Hanna Instruments HI7640-58 User manual

INSTRUCTION MANUAL
Hanna Instruments Inc., 584 Park East Drive, Woonsocket, RI 02895 USA www.hannainst.com
HI7640-58
HI510 Compatible
Please scan the QR code or follow the link
to download the HI510 controller user manual.
https://manuals.hannainst.com/HI510
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0 to 50 ppm (mg/L)
T: -5 to 50 °C
pmax: 2 bar
SN: XXXXXXXXXXXX
HI7640-5805
0 to 50 ppm (mg/L)
T: -5 to 50 °C
pmax: 2 bar
SN: XXXXXXXXXXXX
HI7640-5800
Optical Dissolved Oxygen
Industrial Smart Probes

All rights are reserved. Reproduction in whole or in part is prohibited without the written consent of the copyright owner,
Hanna Instruments Inc., Woonsocket, Rhode Island, 02895, USA.
Hanna Instruments reserves the right to modify the design, construction, or appearance of its products without advance notice.
TABLE OF CONTENTS
1. Preliminary Examination ................................................................................................................3
2. Safety Measures............................................................................................................................3
3. General Description & Intended Use ................................................................................................3
4. Main Features...............................................................................................................................4
5. Series Configuration.......................................................................................................................4
6. Specifications................................................................................................................................5
7. Probe Dimensions & Cable Connection.............................................................................................6
8. Probe Preparation & Conditioning....................................................................................................6
9. Installation ...................................................................................................................................7
10. Wiring the Probe to the Controller................................................................................................10
11. Calibration................................................................................................................................10
12. Maintenance.............................................................................................................................12
13. Accessories................................................................................................................................14
14. Abbreviations............................................................................................................................14
Certification......................................................................................................................................15
Recommendations for Users...............................................................................................................15
Warranty .........................................................................................................................................15
Dear Customer,
Thank you for choosing a Hanna Instruments®product.
Please read this instruction manual carefully before using this instrument as it provides the necessary
information for correct use of this instrument as well as a precise idea of its versatility.
This release of the product manual contains information that applies to configuration, specification, installation,
and calibration of Hanna Instruments industrial optical Dissolved Oxygen probes.
The HI510 controller is sold separately. Please refer to the controller manual for details on system configurations.
If you need additional technical information, do not hesitate to e-mail us at [email protected].
Visit www.hannainst.com for more information about Hanna Instruments and our products.

3 Preliminary Examination
1. PRELIMINARY EXAMINATION
Remove the probe and accessories from the packing and examine it carefully.
Each probe is supplied with:
• HI764113-1 DO Smart Cap with O-ring
• Calibration beaker
• Sachet with silicone grease
• Syringe
• Quick reference guide with probe quality certificate
Note: Save all packing material until you are sure that the probe works correctly. Any damaged or defective item
must be returned in its original packing material with the supplied accessories.
2. SAFETY MEASURES
General Safety & Installation Recommendations
•
Electrical connection, installation, operation, and maintenance must be carried out by specialized
personnel only.
The specialized personnel must read, understand, and adhere to the instructions in this manual.
•
Before connecting the probe to the process controller, disconnect the controller from the power line.
• User serviceable connections are all accessible inside controller’s enclosure.
• Before powering the controller, verify the probe wiring has been done following the instructions
detailed in this manual.
3. GENERAL DESCRIPTION & INTENDED USE
The HI7640-58 series are optical dissolved oxygen probes with Smart Caps (HI764113-1) for measurement
of dissolved oxygen.
The series is designed to work with the Hanna Instruments®HI510 Universal Process Controller. When paired with
the controller, the system provides accurate dissolved oxygen measurements auto-compensated for barometric
pressure, salinity (set manually), and temperature.
Suitable for control applications in aeration basins, ponds, and tanks where optimizing oxygen transfer is a
key element, the probe can be submersed/immersed in a tank using the 3/4” NPT threads, or installed in a
flow cell using the lower sensor threads.
The probe is available with an integral connector that permits connections with no twisted cables as cables
are connected after installation.
Patch cables may be purchased separately to connect between the probe and controller up to 50 meters (164 ft).

Main Features 4
Principle of Operation
The method is based on the principle of fluorescence quenching and features an immobilized Pt- based
luminophore that is excited by the light of a blue LED and emits a red light. Dissolved oxygen quenches this
excitation. When there is no oxygen present, the lifetime of the signal is the greatest; as oxygen hits the sensing
surface, the lifetime becomes shorter.
The intensity and lifetime are inversely proportional to the amount of oxygen present; as oxygen interacts with
the luminophore it reduces the intensity and lifetime of the luminescence. The lifetime of the luminescence is
measured by a photodetector, and is used to calculate the dissolved oxygen concentration. This is, in turn,
reported by the HI510 controller as % saturation or mg/L of dissolved oxygen.
Over time, the sensor’s optical components can age but are compensated for by using the reference signal to
compensate the measuring path. As a result, the sensor provides accurate dissolved oxygen measurements over
long periods of time without the need for frequent calibrations.
4. MAIN FEATURES
• Factory calibrated Smart Cap for data storage
• 3/4” NPT external thread at both ends
• Built-in temperature sensor for measurement
• Digital probe stores model, firmware, serial number, calibration information and Smart Cap data
(serial number, installation date)
• Minimum maintenance (no electrolyte refill or membrane replacement)
• Measurement reliability independent of flow rate
• Reduced response time
• Stable readings even when oxygen concentration is low
5. SERIES CONFIGURATION
HI7640 –5 8 z z
5Optical DO sensor
8Smart probe with RS485 connection
zz 00 supplied with DIN connector (without cable)*
05, 10, 15, 25, 50 fixed cable length (in meters)
* See Accessories section for patch cable ordering codes.

5 Specications
6. SPECIFICATIONS
Range 0.00 to 50.00 mg/L (ppm) concentration
0.0 to 500.0 % saturation
Resolution 0.01 mg/L (ppm)
0.1 % saturation
Accuracy
from 0.00 to 20.00 mg/L (ppm) 1.5 % of reading or ± 0.01 mg/L (ppm), whichever is greater
from 20.00 to 50.00 mg/L (ppm) ±5% of reading
from 0.0 to 200.0 % saturation ±1.5 % of reading or ± 0.1 %, whichever is greater
from 200.0 to 500.0 % saturation ±5 % of reading
Calibration
One or two points at 100 % and/or 0 % or 8.26 mg/L and/or 0 mg/L
in water-saturated air or zero-oxygen solution
Single point process calibration using value entered by the user in % saturation or mg/L
Temperature
Range −5.0to50.0°C(23.0to122.0°F)
Resolution 0.1°C/0.1°F
Accuracy ±0.3°C/±0.5°F
Calibration Single point offset (controller setting)
Temperature
compensation Automatic
Temperature
source
Automatic (from probe)
Manual
Pressure
compensation Automatic 420 to 850 mmHg
Salinity
compensation Automatic 0 to 70 g/L (salinity factor set by user)
Body ABS
Sensor
Type Optical DO
Diameter Ø 17 mm (0.7”)
Insertion length 43 mm (1.7”)
Maximum
pressure 2bar(29psi)at25°C(77°F)
Threaded
connection 3/4” NPT external thread (both ends)
Wetted parts
Sensor body PVDF
Smart cap material Polypropylene
Dome-shaped membrane PMMA
O-ring NBR
Temperature contact Stainless steel
Protection
rating IP68
Cable length See zz, Series Configuration

Probe Dimensions & Cable Connection 6
7. PROBE DIMENSIONS & CABLE CONNECTION
3/4’’ NPT
Ø 17 mm (0.7”)
Ø 28 mm (1.1”)
3/4’’ NPT
172 mm (6.7”)
64 mm (2.5”)
43 mm (1.7”)
172 mm (6.7”)
Align the pins and key then push the plug into the socket.
Rotate the collar to lock in place.
Note: Probe connection (probe with integral DIN connector) and probe wiring (probe with attached cable) must be
carried out with the controller disconnected from power.
8. PROBE PREPARATION & CONDITIONING
Note: Read all the steps prior to starting probe preparation.
1. Invert the probe so the cable faces the floor.
2. Remove the protective cap.
3. Locate the O-ring that sits on probe body.
Sparingly lubricate with a thin film of supplied grease. Use care to prevent grease/fingerprints from
contacting the optical window.
4. Remove the Smart Cap from the container.
5. Align the notched cutout arrow on the Smart Cap with the matching guide on the probe body.
6. Slide and press the Smart Cap onto the probe’s body until the cap snaps in place.
Once the cap is installed, it should not be removed unless a new cap is required.
7. Place the probe in purified water for a minimum of 2 hours to hydrate the Smart Cap before use.
Note: If the probe will not be installed immediately, place in the calibration/storage vessel with fresh water to
protect it from damage and hydrate the cap.

7 Installation
8
7
6
5
4
2
1
3
DETAIL
1. Smart Cap
2. Alignment key
2. Sensor body
4. Temperature sensor
5. Embedded O2 sensitive
luminophore with black
protective layer
6. RFID Tag
7. Optical window
8. O-Ring Seal
1 Smart Cap
2 Alignment key
3 Probe body
4 Temperature sensor
5Embedded O2sensitive luminophore with rugged,
insoluble black oxygen-permeable protective layer
6 Data storage tag
7 Optical window
8 O-ring seal
Note: Verify time and date are configured correctly in the controller’s Setup Menu prior to probe initialization.
9. INSTALLATION
General considerations
• Probes are easily installed using the 3/4” NPT external threads.
• Hand tighten the probe in position. Then, depending on the process, tighten one or two turns with a
wrench to secure in place. Do not exceed 10 N•m (7.3 lb-ft) torque specification for the probe sensor.
• Protect the probe and the Smart Cap from strong flow to prevent unstable readings. In turbulent aeration
basin installations, place the probe in a weir for more accurate readings.
• Position the probe so that it does not trap air bubbles at the Smart Cap.
• Deposits of foreign material should not be allowed to accumulate within the sensing area.
• Protect the sensing surface from any blunt objects and keep it clean.
• Provisions must be made for the removal of the probe from the process
• Consider probe accessibility for maintenance when selecting placement.

Installation 8
Typical installation examples with mounting accessories
Accessories are sold separately.
User-assembled, top thread immersion installation
I
II
1
2
4
3
5
6
To install the probe:
A. Wrap Teflon™ tape around upper 3/4” NPT threads of the probe (6).
B. Attach a user-supplied reducer bushing (5) to the probe (6) upper threads, step I.
C. Feed probe cable through length of NPT externally threaded, user supplied pipe (4), matched to bushing.
D. Thread the pipe into the upper threads of the reducing bushing (5) attached to the probe.
E. The upper portion of the pipe should be sealed, step II, to prevent ingress of water if installed outdoor.
F. Attach the pipe to a handrail.
Low thread immersion installation
The HI60501 (PVC submersible holder) together with HI60501-2 (protective end cap), and HI605011 (mounting
flange) provide a sturdy, protective housing designed for low-thread immersion installation.
1 Cable gland
2 Pipe cap (socket connect or threaded)
3 Van Stone flange (one size smaller than the pipe)
4 2”, or similar, PVC pipe (schedule 80 PVC)
5
Reducer bushing
• internal thread to fit probe’s 3/4” NPT threads
• external thread to fit pipe’s threads or
socket-connect type
6 Optical dissolved oxygen probe

9 Installation
Flow-cell installation
•
The circulation pipes from the tank to the flow-cell must be thermally insulated. Avoid temperature
differencesgreaterthan2°C(36°F)betweentankcontentandflowcellsample.
• Shade the assembly from direct sunlight.
TANK
VALVE 1
VALVE 2
FLOWFLOW
INCOMING FLOW
EXIT FLOW
3
12
4
5
7
6
6
FLOW CELL
1 Process controller
2 Wiring cable
3 Optical DO probe
4 Flow-cell adapter
5 Flow cell
6 Flow-cell valves
7 Saddle

Wiring the Probe to the Controller 10
10. WIRING THE PROBE TO THE CONTROLLER
1. With the controller disconnected from power, run the probe cable through the conduit opening.
2. Connect the probe leads to the removable terminal connector marked PROBE. Follow the lead markings
(+) positive / (–) negative to ensure correct wiring position for output leads.
3. Carefully put the wired terminal connector into place on the board.
4. Position excess cable through cable gland before tightening the nut.
5.
Remove the ground screw and hardware located below the PROBE connector and attach ground lead ( g).
COMM
-BA+
IN1 IN2 A01 A02 A03 A04
PROBE
-BA+
PROBE
-BA+
A+
B
—
Probe cabling color code
Marking Attached cable Patch cable * Functionality
– GREEN BLACK 0V
B WHITE WHITE RS485 D –
A YELLOW BLUE RS485 D+
+ BROWN RED 5V
gGREEN-YELLOW Protective ground connection
* See Accessories section for cable ordering codes.
Note: Ensure wiring regulations are correctly followed when controller unit is part of a larger industrial installation.
11. CALIBRATION
HI510 controller allows two types of dissolved oxygen calibration procedures:
• Standard single or two-points calibration using water-saturated air or air-saturated water and a zero-
oxygen solution to verify that the probe is working correctly and establish a slope
• Process single-point calibration performed with the calibrated probe (two points) installed in the process.
Process calibration allows the user to adjust the measured dissolved oxygen value to match the value
determined with a reference device.